VESPA PX 150 USA Workshop Manual Download

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WORKSHOP MANUAL

633376

Vespa PX 150 USA

Summary of Contents for PX 150 USA

Page 1: ...WORKSHOP MANUAL 633376 Vespa PX 150 USA ...

Page 2: ...WORKSHOP MANUAL Vespa PX 150 USA ...

Page 3: ...ls Refer to the pages of this manual concerning specific tools and equipment and the special tools catalogue N B Provides key information to make the procedure easier to understand and carry out CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle WARNING Refers to specific procedures to carry out to prevent injuries to the repairer Personal safety Failure to co...

Page 4: ......

Page 5: ...OF TOPICS CHARACTERISTICS CHAR TOOLING TOOL MAINTENANCE MAIN ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS CHASSIS CHAS PRE DELIVERY PRE DE TIME TIME ...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 7: ...n is harmful Maintenance rules Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer Non original or non conforming spares may damage the vehicle Use only the appropriate tools designed for this vehicle Always use new gaskets sealing rings and split pins upon refitting After removal clean the components using non flammable or low flash point solvents Lubricate all the wor...

Page 8: ... 57 mm Cilindrata 150 919 inch3 150 599 cm3 Compression ratio 150 8 1 Carburetor Dell orto SI 20 20 D Engine idle speed 1900 100 rpm CO value 3 8 0 5 Air filter Metallic net soaked in oil petrol mixture Starting system Electric starter motor and kick start Lubrication Mixture oil Fuel supply Oil petrol mixture through carburetor with automatic mixer mass flow varying with engine speed and throttle...

Page 9: ...Quantity 1 Ignition type Electronic ignition by capacitive discharge with H T coil 2 Spark advance T D C 18 1 3 Spark plug CHAMPION RL82C 4 Battery 12V 9Ah 5 Fuse 7 5 A 6 Generator AC Frame and suspensions FRAME AND SUSPENSIONS Specification Desc Quantity Suspensions Steering column pivoted onto front wheel hub helicoid spring suspension and hydraulic shock absorber compression and rebound damping...

Page 10: ...ND ACCESSORIES Carburettor Dell Orto CARBURETTOR Specification Desc Quantity Type SI20 20D Diffuser diameter 20 mm Main jet 96 100 Slow running jet 45 100 Main air jet 140 100 Throttle valve type 6823 09 Emulsifier code BE5 Sprayer 280 100 Starter jet 60 100 Air idling screw 1 2 turn With idling air hole 140 100 150cc Version Dell Orto CARBURETTOR Specification Desc Quantity Type SI20 20D Diffuser...

Page 11: ...per fitting 15 25 Intermediate pipe fitting 10 15 Calliper fixing screw 20 25 Disc fixing screw 5 6 Oil draining screw 10 12 ENGINE Name Torque in Nm Coils mounting bracket fixing screw 3 4 Kick start lever fixing nut 23 26 Clutch assy fixing nut 40 45 Multi gear pinion nut 30 35 Flywheel fixing nut 60 65 Carburettor fixing bolts 16 20 Clutch cover fixing screws 6 8 Cylinder head fixing nuts 13 18...

Page 12: ...0 240 Cylinder piston E 57 810 57 570 0 240 Cylinder piston F 57 815 57 575 0 240 Cylinder piston G 57 820 57 580 0 240 Cylinder piston H 57 825 57 585 0 240 Cylinder piston 1st oversize C 58 000 57 760 0 240 Cylinder piston 1st oversize D 58 005 57 765 0 240 Cylinder piston 1st oversize E 58 010 57 770 0 240 Cylinder piston 1st oversize F 58 015 57 775 0 240 Cylinder piston 1st oversize G 58 020 ...

Page 13: ...on 3rd oversize D 58 405 58 165 0 240 Cylinder piston 3rd oversize E 58 410 58 170 0 240 Cylinder piston 3rd oversize F 58 415 58 175 0 240 Cylinder piston 3rd oversize G 58 420 58 180 0 240 Piston rings PISTON RINGS 150CC ENGINE Name Description Dimensions Initials Quantity Piston ring 57 8 A 0 2 0 4 Piston ring 1st over size 58 A 0 2 0 4 Piston ring 2nd over size 58 2 A 0 2 0 4 Piston ring 3rd o...

Page 14: ...NKSHAFT ON FLYWHEEL SIDE Name Description Dimensions Initials Quantity Connecting Rod B 15 6 0 1 0 2 F 0 05 0 41 Washer 2 G 0 5 0 05 0 03 F 0 05 0 41 Half crankshaft clutch side C 11 1 0 0 05 F 0 05 0 41 Half crankshaft fly wheel side D 11 1 0 0 05 F 0 05 0 41 Spacer tool H 38 95 Connecting rods and roller cages are subdivided into 4 categories indicated by markings on big end and outer cage rim r...

Page 15: ... PLAY TO CHECK THE CLEARANCE USE A FEELER GAUGE Products TABLE OF RECOMMENDED PRODUCTS Product Description Specifications AGIP GEAR 80W 90 gearbox oil SAE 80W 90 oil complying with API GL4 specifications AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions brake throttle control and mixer odom eter Oil for 2 stroke engines SAE 5W 40 API SL ACEA A3 JASO MA AGIP GP 330 Grease brake level thro...

Page 16: ...INDEX OF TOPICS TOOLING TOOL ...

Page 17: ...r removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment 002850y Oil tank spanner 002973y Fuel tap spanner 020320Y Exhaust gases analyser Vespa PX 150 USA Tooling TOOL 17 ...

Page 18: ...Description 020325Y Brake shoe spring calliper 020329Y MityVac vacuum operated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rev counter Tooling Vespa PX 150 USA TOOL 18 ...

Page 19: ...Stores code Description 020333Y Single battery charger 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge 001330Y Tool for fitting steering seats Vespa PX 150 USA Tooling TOOL 19 ...

Page 20: ...service tool 020321y Carburettor float removing tool 006029Y Punch for fitting fifth wheel seat on steer ing tube 020625Y Kit for sampling gas from the exhaust manifold 001467Y021 Extraction pliers for ø 11 mm bearings Tooling Vespa PX 150 USA TOOL 20 ...

Page 21: ...n 020151Y Air heater 020150Y Air heater support 020057Y Calking tool 020095Y Flywheel retaining tool 008564Y Flywheel extractor 008886Y Crankshaft extractor 004499Y Camshaft bearing extractor Vespa PX 150 USA Tooling TOOL 21 ...

Page 22: ...265Y Bearing fitting base 060007Y Crankcase bearing spacer 060824Y Inspection probe 008119Y009 Tube to assemble shafts and axles 001729Y Clutch retaining tool 020322Y Clutch removing fitting tool Tooling Vespa PX 150 USA TOOL 22 ...

Page 23: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 24: ...condition and wear Brake fluid level check Electrical system and battery check Tyre condition and wear Check Vehicle and brake test road test AT 6213 71 MILES OR 24 MONTHS 130 Action Gear box oil level replacement Spark plug replacement Air filter on carburetor Clean Idle speed adjustment Transmission gas mixer adjust Odometer gear greasing Steering adjustment Brake and clutch lever greasing Brake...

Page 25: ...pensions check Electrical system and battery check Headlight adjustment check Tyre condition and wear Check Vehicle and brake test road test See in section Idling speed adjustment AT 15534 MILES 65 Action Gear box oil level check Spark plug replacement Air filter on carburetor Clean Transmission gas mixer adjust Brake and clutch lever greasing Brake pads check condition and wear Brake fluid level ...

Page 26: ...n Idle speed adjustment Cylinder cooling system check cleaning Transmission gas mixer adjust Odometer gear greasing Steering adjustment Brake and clutch lever greasing Brake pads check condition and wear Brake fluid level check Transmission elements lubrication Safety locks check Suspensions check Electrical system and battery check Headlight adjustment check Tyre condition and wear Check Vehicle ...

Page 27: ...xer adjust Brake and clutch lever greasing Brake pads check condition and wear Brake fluid level check Electrical system and battery check Tyre condition and wear Check Vehicle and brake test road test AT 37282 MILES 205 Action Gear box oil level replacement Spark plug replacement Air filter on carburetor Clean Idle speed adjustment Cylinder cooling system check cleaning Transmission gas mixer adj...

Page 28: ...n Desc Quantity Conical needle Float Emulsifier air adjusting screw Emulsifier Main jet Slow running jet Fuel flow adjusting screw Throttle valve adjusting screw Throttle valve Starter jet Choke device Checking the spark advance In order to ensure the correct timing check the stator is oriented so that the I T index see figure coincides with the marking found on the crank case To check the timing ...

Page 29: ...ling washer is in good state Refit the spark plug by screwing it in by hand and tightening it at the prescribed torque using a box spanner Electric characteristic Spark plug CHAMPION RL82C Spark gap 0 5 0 6 mm Locking torques N m Spark plug 25 30 Nm Air filter Remove the engine cowling and the air box cov er by loosening the four fixing screws shown in the figure and the idle adjusting screw hence...

Page 30: ...N STANDARDS REGARDING MAXIMUM AND MINI MUM HEIGHT OF LIGHT BEAMS REFER TO THE STATU TORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE vehicle IS USED Gearbox Oil Check for the presence of oil inside the gearbox oil capacity 8 82 oz 250 g with the vehicle axis perfectly ver tical the oil level must be at the height of inspection hole A To replace the oil drain the box using filler hole B Pour so...

Page 31: ...Vespa PX 150 USA Maintenance MAIN 31 ...

Page 32: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 33: ...n button 5 Horn 6 2 yellow lights for turn signal lights 7 Front left turn indicator 8 Heater control device 9 Flywheel magneto 10 Electronic ignition device 11 Starter motor 12 Fuse carrier N 1 fuse to 7 5 A 13 Battery 14 rear left turn indicator 15 Direction indicator lights N 2 16 Rear parking and stop light bulbs 17 Rear light assembly 18 rear right turn indicator Vespa PX 150 USA Electrical s...

Page 34: ...t turn indicator 29 Key switch 30 Starter button 31 Front brake stop button 32 Headlight 33 Light 34 Sidelight bulb 35 Left turn indicator warning light 12V 2W 36 Headlamp warning light 37 High beam lamp warning light 38 License plate light bulb 39 Low fuel warning light 40 Right turn indicator warning light 12V 2W 41 Low oil warning light 42 Odometer with warning lights and level indicator Electr...

Page 35: ...trol Unit C D I with H T coil 4 Battery 12V 9Ah 5 Starter motor 6 Magneto flywheel 7 Anti repeating device 8 Spark plug 9 Remote starter switch 10 Fuse 7 5 A 11 Horn 12 Turn signals master box 13 Front headlight 14 Front turn signal lights 15 Taillight 16 Rear turn signal lights Vespa PX 150 USA Electrical system ELE SYS 35 ...

Page 36: ...ptual diagrams Ignition IGNITION Specification Desc Quantity 1 Magneto flywheel 2 Key switch contacts 3 Electronic Control Unit C D I with H T coil 4 Spark plug Electrical system Vespa PX 150 USA ELE SYS 36 ...

Page 37: ... 3 Key switch contacts 4 Lampada proiettore 12V 55 60W 5 High beam warning light 12V 1 2W 6 Light switch 7 Light remote control switch 8 Rear side light bulb 12V 5W 9 Instrument panel lighting bulb 12V 1 2W 10 Headlamp warning light 12V 1 2W 11 Fuse 7 5A 12 Battery 12V 9Ah Vespa PX 150 USA Electrical system ELE SYS 37 ...

Page 38: ...l 2 Electronic ignition device 3 Key switch contacts 4 Voltage regulator 5 Fuse 7 5 A 6 Remote starter switch 7 Starter motor 8 Battery 12V 9Ah 9 Enable button 10 Start up button 11 Anti repeating device 12 Engine stop switch 13 Engine stop remote control switch Electrical system Vespa PX 150 USA ELE SYS 38 ...

Page 39: ... SAFETY SWITCHES AND LEVEL GAUGES Specification Desc Quantity 1 Fuel gauge 2 Fuel level sending unit 3 Reserve fuel light 12V 1 2W 4 Brake light bulbs 12V 10W 5 Stoplight switches 6 Voltage regulator Vespa PX 150 USA Electrical system ELE SYS 39 ...

Page 40: ...uantity 1 Turn signals master box 2 Indicators switch 3 Turn signal warning light 12V 1 2W 4 Turn signal light bulbs 12V 21W 5 Horn button 6 Horn 7 Voltage regulator 8 Key switch contacts 9 Fuse 7 5A 10 Battery 12V 9Ah Electrical system Vespa PX 150 USA ELE SYS 40 ...

Page 41: ...ht 7 Ground lead Checks and inspections Ignition circuit All system checks requiring the detachment of ca bles inspections involving ignition system wiring and devices must be carried out with the engine off so to avoid any possible damage to the ECU which would require its replacement It is therefore important to follow the wire color coding when reattaching the cables see figure Vespa PX 150 USA...

Page 42: ... be attributed to a defective CDI device In the event that the ignition system is still mal functioning it will be necessary to check the gen erator and the stator components as follows After an eye inspection of the connections per form measurements on recharge coil and pick up see table using the specified tester If such read ings do not match the stated values proceed by replacing the stator an...

Page 43: ...nce of a reg ulator voltage exceeding 15V replace the regula tor as definitely faulty FAULT 2 a Check the correct current supply from the alter nator detach the regulator connector and attach the alternate current tester between the grey blue wire terminal and earth With the tester set onto alternate current check the supplied voltage at 3 000 rpm is between 25 and 30V b If no faults are found rep...

Page 44: ...rpm this measurement must obvi ously be carried out with the battery disconnec ted Specific tooling 020331Y Digital multimeter Starter motor Bench tests to be performed on the electric starter motor 1 No load test the starter motor unloaded must absorb less than 10 A with a voltage supply 11 7 V and must spin at more than 18 000 rpm 2 Load test load the starter motor so that the absorbed current i...

Page 45: ...ocated on the LHS of the battery tray Before replacing a burst fuse it is necessary to find the cause of the failure Never attempt to close the circuit with any material other than the fuse CAUTION BEFORE REPLACING A BLOWN FUSE FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW NEVER TRY TO REPLACE THE FUSE WITH ANY OTHER MATERIAL E G A PIECE OF ELECTRIC WIRE CAUTION MODIFICATIONS OR REPAIRS TO THE...

Page 46: ... and or dwg 020334Y select the battery capacity If the battery charger is not available charge the battery with a constant current of 1 10 of the rated capacity for example for a battery with rated capacity of 9Ah the charge current must be 0 9 1 0A for approx 4 6 hours Note Batteries stored for a long time can require longer times Battery chargers dwg 020333Y and dwg 020334Y have an automatic pro...

Page 47: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 48: ...of the engine from the vehicle Remove the exhaust assy Remove the rear wheel Detach the rear brake cable Detach the electrical wires Detach the gear shifter cables Remove the throttle and choke cables Detach the oil and petrol hoses Remove the engine frame bolt shown in the fig ure Engine from vehicle Vespa PX 150 USA ENG VE 48 ...

Page 49: ...scribed tightening torques CAUTION WHEN INSTALLING THE BATTERY ATTACH THE POSI TIVE LEAD FIRST AND THEN THE NEGATIVE LEAD WARNING Wear safety goggles when using hitting tools WARNING Be very careful when handling fuel Locking torques N m Engine frame bolt 61 75 Shock absorber engine bolt 13 23 Vespa PX 150 USA Engine from vehicle ENG VE 49 ...

Page 50: ...INDEX OF TOPICS ENGINE ENG ...

Page 51: ...he cooling hood Remove the fixing screws shown and hence de tach the volute and the gear shifter cover Remove the kick start lever after having detach ed the lower fastener Removing the stator Remove the three screws shown in the figure Remove the stator Vespa PX 150 USA Engine ENG 51 ...

Page 52: ...or Remove the two screws and detach the drive box from the starter motor With the aid of a hacksaw abrade the pinion head ring Using two screwdrivers detach the cap Remove the retaining ring shown by the arrow in the figure and remove the pinion components WARNING THE PACKING ON THE MATING SURFACE MUST AL WAYS BE REPLACED WITH A NEW ONE USING LOC TITE Engine Vespa PX 150 USA ENG 52 ...

Page 53: ...gear with the air heater refit the drive shaft with all the components previ ously removed Refit the remaining components following the above operations in the reverse order Specific tooling 001467Y Extractor for bearings for holes 001467Y021 Extraction pliers for ø 11 mm bear ings 020151Y Air heater 020150Y Air heater support Position a new cap onto the pinion and round the edges using the specia...

Page 54: ...cover detach the drive gear retaining pin and remove the gear Refit the assembly components in the reverse order Removing the flywheel magneto Retain the flywheel using the special tool hence remove the lock nut Specific tooling 020095Y Flywheel retaining tool Remove the flywheel retaining tool Extract the flywheel using the special extractor Specific tooling 008564Y Flywheel extractor Engine Vesp...

Page 55: ...arms and fay ing surface of driven pulley spring only pulley side Soap based lithium and zinc oxide grease con taining NLGI 2 ISO L XBCIB2 Locking torques N m Flywheel fixing nut 60 65 Cylinder assy and timing system Removing the cylinder head Loosen the four nuts and remove the cylinder head Removing the cylinder piston assy After removing the cylinder detach the wrist pin re taining rings and he...

Page 56: ...ng particular attention to positioning the piston with the arrow marking on the crown pointing toward the exhaust port Locking torques N m Head fixing nuts 16 26 Crankcase crankshaft Splitting the crankcase halves Remove the twelve fasteners and split the two crankcase halves carefully using a plastic or hard rubber mallet CAUTION WITH A RUBBER BAND TIE THE CONNECTING ROD TO THE TWO STUDS ON THE C...

Page 57: ...s for inter nal split rings remove the bearing retaining ring shown From the side opposite that shown in the figure and with the aid of a flat head puncher extract the bearing Using the special extractor remove the roller bearing from the crankshaft Specific tooling 004499Y Camshaft bearing extractor Using the special extractor remove the roller bearing from the crankcase Vespa PX 150 USA Engine E...

Page 58: ... already done for the clutch side half crankcase focusing exclusively on the bearing housing Position the bearing using a length of tube push ing directly on the bearing s outer ring Position the crankshaft onto the special support Install the special spacer as shown in the figure and using a length of tube of adequate diameter push the bearing until the inner ring heated up in oil at 248 F or 120...

Page 59: ...d throttle opening Important whenever the mixer device has been removed overhauled or refitted there may be no oil inside the ducts To allow the mixer to safely fill these ducts with oil it is suggested that the fuel tank 1 in the figure is first refilled with approx 3 l of mixture containing 2 of SELENIA HI SCOOTER 2T oil Once this first quantitative has been exhausted any further refill must obv...

Page 60: ...er cap Oil tank filler cap Oil level gauge SEPARATE LUBRICATION device box Oil inlet hose Oil outlet hose Oil outlet valve A Inlet phase B Outlet phase Oil pump Remove the carburettor box Remove the mixer drive shaft from its housing Engine Vespa PX 150 USA ENG 60 ...

Page 61: ...d then use pli ers for internal split rings to remove the mixer body Refit the components following the removal pro cedure in the reverse order paying attention in positioning the pump body correctly in its housing so to be able to easily insert the retaining screw See also Removing the carburettor Vespa PX 150 USA Engine ENG 61 ...

Page 62: ...ing screws and the carburetor cover Remove the fasteners and the air filter After removing the air filter loosen the two 8mm Allen screws and hence remove the carburetor Loosen the fixing screw and remove the carbu retor body Engine Vespa PX 150 USA ENG 62 ...

Page 63: ...and blow with compressed air Loosen the fixing screw and remove the float bowl Remove the starter jet and blow with com pressed air Remove the float pin to release the float and hence the conical needle Vespa PX 150 USA Engine ENG 63 ...

Page 64: ...WARNING PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE GASKETS TO AVOID PETROL LEAKS Manual Gear Shifter Remove the fasteners and the gear shifter From the side opposite to that shown in the figure and with the aid of a puncher remove the conical pin and extract the gear shifting lever Engine Vespa PX 150 USA ENG 64 ...

Page 65: ...nd extract the gears Using a plastic mallet remove the shaft Remove the multiple gear shaft lock nut Remove the multiple gear shaft using a mallet from the side opposite to that shown in the figure Do not let the 21 rollers composing the bearing fall onto the ground Vespa PX 150 USA Engine ENG 65 ...

Page 66: ... side opposite to that shown in the figure After removing the retaining washer shown in the figure remove the fastener underneath it hence extract the even tension gear Remove the rivet head and replace any faulty component Refit the components using new rivets Replace the trunnion if worn CAUTION THE TRUNNION BUSHING HAS A LHS THREAD Locking torques N m Gear box trunnion 15 18 Engine Vespa PX 150...

Page 67: ...the 21 rollers using the recommended grease to keep them in place during the reassem bly With the refitting operation concluded tighten the shaft lock nut to the prescribed torque Recommended products AGIP GREASE MU3 Grease for odometer transmission gear case Soap based lithium grease with NLGI 3 ISO L XBCHA3 DIN K3K 20 Locking torques N m Multi gear pinion nut 30 35 Before proceeding by refitting...

Page 68: ...ving the gear shaft Specific tooling 008119Y009 Tube to assemble shafts and axles See also Splitting the crankcase halves Clutch Remove the 3 fixing screws and the clutch cover With the aid of a screwdriver remove the bal ance screw Engine Vespa PX 150 USA ENG 68 ...

Page 69: ...001729Y Clutch retaining tool Remove the mixer drive gear from its housing Using the special tool remove the clutch discs Specific tooling 020322Y Clutch removing fitting tool Check the conditions of all components and the camber of the metal discs A camber smaller than the prescribed one may cause slippage Refit the clutch assembly components inverting the order followed for the disassembly Vespa...

Page 70: ...ng Refit the clutch assembly onto the engine and tighten the locknut using the special retainer Refit the remaining components in following the procedures carried out from their removal in the reverse order Specific tooling 001729Y Clutch retaining tool Locking torques N m Clutch assy fixing nut 40 45 Engine Vespa PX 150 USA ENG 70 ...

Page 71: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 72: ... on the outer side of the wheel hub and the seal ring remove the bear ing using a length of pipe of adequate diameter and a mallet as shown in the figure Follow the same procedure to remove the roller cage on the opposite side Handlebar Removal Remove the 2 rear view mirrors and their fixing ring nuts Remove the handlebar cover as described in the Bodywork chapter and the speedometer Suspensions V...

Page 73: ...0055Y Wrench for steering tube ring nut Overhaul Servicing the front suspension steering assembly described below deals mainly with replacing parts pin NADELLA roller bushings sealing rings unit and dust guard which connect the steering tube to the front wheel holder swinging hub N B BEFORE PROCEEDING WITH THE DESCRIBED SERVICE CHECK THAT THE STEERING TUBE AND THE WHEEL HOLDER HUB ARE IN EXCELLENT...

Page 74: ...hown in the figure N B DURING THE REMOVAL OPERATIONS DESCRIBED ABOVE THE ROLLER BUSHINGS ARE DESTROYED WHEN THE EXTRACTOR IS USED UPON REFITTING IT IS THEREFORE NECESSARY TO USE NEW BUSHINGS AS WELL AS A NEW PIN NEW SEALING RINGS AND DUST GUARDS Specific tooling 020021Y Front suspension service tool Connect the swinging hub to the steering tube with the guiding pin Use the tool fitted with part 3 ...

Page 75: ...ated in the figure to fit the second wedging washer roller bushing sealing ring unit WARNING BEFORE PROCEEDING WITH THE DESCRIBED PRE FIT TING DIP THE SEALING RINGS IN MINERAL OIL AND THE NADELLA ROLLER BUSHINGS PREVIOUSLY WASHED IN PURE PETROL OR NEUTRAL PETROLEUM TO ELIMI NATE THE ANTIRUST PROTECTION HALF FILLED WITH GREASE Specific tooling 020021Y Front suspension service tool Recommended produ...

Page 76: ...O L XBCHA3 DIN K3K 20 To remove the bearing housings from the frame use the special tool shown in the figure Specific tooling 020004Y Punch for removing fifth wheels from headstock Using the special tool remove the bearing and dust ring housings from the steering column as shown in the picture Proceed with mallet hits Specific tooling 020004Y Punch for removing fifth wheels from headstock Using th...

Page 77: ...wist grip gaer Calcium complex soap grease NLGI 2 ISO L XBCIB2 Locking torques N m Top steering housing 6 7 hence loosen by 80 90 Upper steering ring nut 5 6 Front shock absorber Removal Remove the 2 fixings shown in the figure and the 2 fasteners on the shock absorber support bracket located on the steering column Free the shock absorber from the support bracket removing the top fixing Shock abso...

Page 78: ...ng fitted onto the calliper bracket After removing the wheel hub extract the ring shown in the figure and replace it with a new one Rear Removing the rear wheel After removing the spare wheel remove the three fasteners shown in the figure Remove the rear wheel by loosening the five fix ing screws Refitting the rear wheel When refitting the rear wheel tighten all fasteners at the prescribed torque ...

Page 79: ...remove the engine shock absorber fixing bolt as shown in the figure Remove the gasoline and oil tanks then remove the shock absorber upper fixing in the underseat compartment housing Centre stand Detach the return spring from the centre stand re move the 4 fasteners shown in the figure Vespa PX 150 USA Suspensions SUSP 79 ...

Page 80: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 81: ... IN ORDER TO ENSURE THE CORRECT TIGHTENING TORQUE LUBRICATE NUTS BEFORE AS SEMBLY Locking torques N m Pipe calliper fitting 15 25 Calliper fixing screw 20 25 Front brake disc Removal Remove the rear wheel by loosening the 5 fas teners Remove the wheel hub Loosen the 5 disc fasteners Refitting When refitting correctly position the disc observing the direction of rotation see figure and apply medium...

Page 82: ...oblem is not solved check and if neces sary replace the wheel hub Specific tooling 020335Y Magnetic support for dial gauge Front brake pads Removal To facilitate this operation it is suggested that the front wheel is removed remove the plastic cap and apply leverage with a screwdriver Remove the external split ring from the pin the spring and the pads themselves The pads must be replaced if the th...

Page 83: ...GH THE PUMP WARNING THE BRAKE FLUID IS HYGROSCOPIC I E IT ABSORBS HUMIDITY FROM THE AIR IF THE HU MIDITY LEVEL IN THE FLUID EXCEEDS A GIVEN VALUE THE BRAKING PERFORMANCES MAY SERIOUSLY DETERIORATE IT IS THEREFORE RECOMMENDED THAT FRESH FLUID IS TAKEN FROM NEW CONTAINERS IN NORMAL CLIMATIC CONDITIONS THE FLUID SHOULD BE RE PLACED EVERY TWO YEARS IF THE BRAKES ARE HIGHLY STRESSED INCREASE THE FREQUE...

Page 84: ...ontainer Refitting For refitting perform the operation in the reverse order Tighten the pipe to the prescribed torque and bleed the circuit Locking torques N m Reservoir pipe fitting 8 12 Rear drum brake Remove the rear wheel Straighten the splint pin and remove the lock nut Braking system Vespa PX 150 USA BRAK SYS 84 ...

Page 85: ... prescribed torque WARNING ALWAYS USE NEW SPLIT PINS FOR REFITTING WARNING FOLD THE EDGES OF THE SPLIT PIN AS SHOWN IN OR DER TO AVOID BACKSLASH BETWEEN THE CAP AND THE WHEEL AXLE Locking torques N m Wheel axle nut 90 110 Rear Brake Pedal After loosening the brake fixing on the rear wheel remove the 3 fasteners indicate in the figure Remove the rubber from the pedal and detach the electrical wirin...

Page 86: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 87: ...o speedometer cable to replace the dashboard assembly Once the handlebar is removed act upon the two lips on the dashboard Headlight assy After removing the handlebar cover remove the 2 fasteners show in the figure and the headlight ad justing screw underneath the handlebar Detach the wirings To replace the bulbs simply release the springs holding back the socket and replace any blown bulb Vespa P...

Page 88: ... of the lock body and the new master cylinder on the outer lock body are as follows Carefully clean the body from any impurity if the cylinder has been drilled using compressed air Position the body in its housing after fitting the retaining spring E Insert the cylinder assembly with key and tongue F facing downwards halfway inside the lock body ensuring that during this operation they is in the O...

Page 89: ...lock Should it be necessary to replace the steering lock cylinder when the keys have gone missing pro ceed as follows Cylinder removal in the event that the key switch is in the LOCK position it is necessary to pro ceed by drilling the cylinder with the aid of a Ø8 mm at least 30 mm long this allows to release or destroy the internal retaining device of the drilled cylinder Hence extract the body ...

Page 90: ... with the fuel tap shut to separate the fuel oil tanks Remove the tank filler cap and insert the special tool through the tube Proceed by loosening the nut and the acting upon ring B until releasing the oil tank Specific tooling 020321Y Carburetor float removing tool 002850y Oil tank spanner 002973y Fuel tap spanner Remove the tank filler cap and insert the spanner thus loosening nut D hence extra...

Page 91: ...er removing the handlebar and the steering column assembly remove the 3 fasteners shown in the figure Top case Front Remove the 2 fixings shown in the figure and the 2 top fasteners from inside the glove box Remove the glove box assembly Vespa PX 150 USA Chassis CHAS 91 ...

Page 92: ...the steering column cover remove the horn and the grid fixings Replace the grid Side Cowlings Lift the seat and act upon either one of the two lever according to which cowling must be re moved RHS or LHS Chassis Vespa PX 150 USA CHAS 92 ...

Page 93: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 94: ...EFORE USE INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS BATTERY LIFE WARNING BEFORE RECHARGING THE BATTERY REMOVE THE CAPS OF EACH CELL KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED REMOVE THE BATTERY FROM THE SCOOTER DISCONNECTING THE NEGATIVE TERMINAL FIRST CAUTION WHEN INSTALLING THE BATTERY ATTACH THE POSITIVE LEAD F...

Page 95: ...ank Road test Cold start Speedometer check Throttle check Riding stability Front and rear brake efficiency Front and rear shock absorbers Unusual noises Hot engine restart Leakages after trial run Functional inspection Other Tire pressure All locks Rear view mirrors and accessory fitting Tooling kit owner manual warranty certificate and customer service card CAUTION CHECK THE INFLATING PRESSURES W...

Page 96: ...INDEX OF TOPICS TIME TIME ...

Page 97: ...Engine ENGINE Code Action Duration 1 001001 Engine from the frame removal and refitting 2 003064 Engine oil replacement 3 003057 Engine retainer Tighten nuts Vespa PX 150 USA Time TIME 97 ...

Page 98: ...CRANKCASE BEARINGS Code Action Duration 1 001117 Crankshaft Replacement 2 001118 Crankcase bearings Replacement 3 001099 Oil seal flywheel side Replacement 4 001100 Clutch side oil seal Replacement Time Vespa PX 150 USA TIME 98 ...

Page 99: ...ON CYLINDER ASSY Code Action Duration 1 001002 Cylinder piston Replacement 2 001107 Cylinder Piston Overhaul Cleaning 3 001093 Spark plug Replacement 4 001094 Spark plug cap Replacement Vespa PX 150 USA Time TIME 99 ...

Page 100: ...Flywheel cover FAN COVER Code Action Duration 1 001087 Flywheel cover Replacement Time Vespa PX 150 USA TIME 100 ...

Page 101: ...Oil pump AUTOMATIC MIXER Code Action Duration 1 001018 Mixer Replacement 2 001028 Oil pump drive shaft Replacement Vespa PX 150 USA Time TIME 101 ...

Page 102: ...r gear spring Replace ment 2 001120 Crankcase bearings Replacements 3 001084 Starter lever Replacement STARTER MOTOR Code Action Duration 1 001020 Starter motor change 2 001039 Starter motor brushes Replacement 3 001038 Starter motor Overhaul Time Vespa PX 150 USA TIME 102 ...

Page 103: ...aft Replacement Flywheel magneto FLYWHEEL MAGNETO Code Action Duration 1 001067 Stator Removal and refitting 2 001004 Stator Overhaul 3 001058 Flywheel Replacement 4 001059 Pick up Replacement 5 003052 Ignition timing Vespa PX 150 USA Time TIME 103 ...

Page 104: ...Carburettor CARBURETTOR Code Action Duration 1 001063 Carburettor Replacement 2 001008 Carburatore Revisione 3 003058 Carburettor Adjustment Time Vespa PX 150 USA TIME 104 ...

Page 105: ...Exhaust pipe EXHAUST PIPE Code Action Duration 1 001009 Exhaust pipe Replacement Vespa PX 150 USA Time TIME 105 ...

Page 106: ...Air cleaner AIR CLEANER Code Action Duration 1 001014 Air filter Replacement 2 001027 Air cleaner frame bellow Replace ment Time Vespa PX 150 USA TIME 106 ...

Page 107: ...Frame FRAME Code Action Duration 1 004001 Frame Replacement 2 006001 Frame Painting 3 004023 Shield rim Replacement Vespa PX 150 USA Time TIME 107 ...

Page 108: ...Centre stand CENTRE STAND Code Action Duration 1 004004 Centre stand Replacement Legshield spoiler Time Vespa PX 150 USA TIME 108 ...

Page 109: ...ERING COLUMN FAIRING Code Action Duration 1 004024 Steering column fairing Replace ment Side fairings WHEEL SIDE FAIRINGS Code Action Duration 1 006005 Side fairings Painting Vespa PX 150 USA Time TIME 109 ...

Page 110: ...SIDE FAIRING LOCKS Code Action Duration 1 004025 Side fairing locks Replacement Footrests Time Vespa PX 150 USA TIME 110 ...

Page 111: ... Action Duration 1 004015 Footrests Replacement Rear cover GLOVE BOX Code Action Duration 1 004083 Glove box Replacement 2 006019 Glove box Painting 3 004081 Glove box door Replacement Vespa PX 150 USA Time TIME 111 ...

Page 112: ...Mudguard FRONT MUDGUARD Code Action Duration 1 004002 Front mudguard Replacement 2 006003 Mudguard Painting 3 003045 Steering tube Replacement Time Vespa PX 150 USA TIME 112 ...

Page 113: ...Fuel tank FUEL LEVEL SENSOR Code Action Duration 1 005010 Fuel tank float Replacement Vespa PX 150 USA Time TIME 113 ...

Page 114: ...ion 1 004005 Fuel tank Replacement 2 004007 Fuel tap Replacement 3 004110 Fuel tank hose Replacement 4 006024 Fuel tank Painting Tank oil OIL TANK Code Action Duration 1 004017 Oil tank Replacement Time Vespa PX 150 USA TIME 114 ...

Page 115: ...Rear shock absorber REAR SHOCK ABSORBER Code Action Duration 1 003007 Rear shock absorber Removal and refitting Vespa PX 150 USA Time TIME 115 ...

Page 116: ...EERING COLUMN BEARINGS Code Action Duration 1 003002 Steering bearings Replacement 2 004119 Steering support bearing Replace ment 3 003073 Steering play Adjustment 4 004010 Steering lock Replacement Time Vespa PX 150 USA TIME 116 ...

Page 117: ...Replacement 3 002037 Brake or clutch lever Replacement 4 001035 Clutch lever Replacement HANDLEBAR COMPONENTS AND BRAKE FLUID PUMP Code Action Duration 1 002059 RHS twist grip Replacement 2 002024 Front brake pump Removal and re fitting 3 002047 Front brake fluid Replacement and circuit bleeding Vespa PX 150 USA Time TIME 117 ...

Page 118: ...Code Action Duration 4 002021 Front brake hose Removal and re fitting Seat SEAT Code Action Duration 1 004003 Saddle Replacement 2 004054 Saddle lock catch Replacement Time Vespa PX 150 USA TIME 118 ...

Page 119: ...38 Dashboard warning telltale lights Replacement 2 005014 Odometer Replacement 3 006010 Top handlebar cover Painting 4 004066 Rear view mirror Replacement 5 003001 Top handlebar cover Removal and Refitting 6 006011 Lower handlebar cover Painting Vespa PX 150 USA Time TIME 119 ...

Page 120: ...Turn signal lights HEADLIGHT Code Action Duration 1 005008 Headlight bulbs Replacement 2 005002 Front light Replacement Time Vespa PX 150 USA TIME 120 ...

Page 121: ...LIGHTS Code Action Duration 1 005011 Starter relay Replacement 2 005012 Front turn signal light Replacement 3 005067 Front turn indicator bulb Replace ment 4 005068 Rear turn indicator bulb Replace ment 5 005022 Rear turn signal light Replacement 6 005006 Turn signals switch Replacement 7 005039 Headlight switch Replacement Vespa PX 150 USA Time TIME 121 ...

Page 122: ...ake note that the code has been intro duced 900001 Tone wheel drive greasing 15 Never mistake the codes 002011 movement sen sor replacement and 005089 tone wheel replace ment in the event of noise of the indicated components The grease recommended is TUTE LA MRM 2 soap based lithium grease with Mo lybdenum disulphide In the following points we indicate with an arrow the area to be greased 1 Drive ...

Page 123: ...Electric devices ECU CDI Code Action Duration 1 001023 CPU Replacement Vespa PX 150 USA Time TIME 123 ...

Page 124: ...ELECTRICAL CONNECTIONS Code Action Duration 1 005001 Electric circuit Replacement and Refitting Time Vespa PX 150 USA TIME 124 ...

Page 125: ...05009 Voltage regulator Replacement 2 005007 Battery Replacement 3 004071 Battery compartment Replacement ELECTRICAL DEVICES Code Action Duration 1 005024 Battery fuse Replacement 2 005025 Battery fuse holder Replacement Vespa PX 150 USA Time TIME 125 ...

Page 126: ...ELECTRICAL DEVICES Code Action Duration 1 005013 Electronic blinker Replacement 2 005045 Starter motor wire harness Re placement Time Vespa PX 150 USA TIME 126 ...

Page 127: ... 005069 Left switch Replacement Transmissions CABLES Code Action Duration 1 002008 Choke cable Replacement 2 002056 Gear shifter cable assy Replace ment 3 002051 Odo Speedometer cable assy Re placement 4 002049 Odometer cable Replacement 5 002046 Gear shifter cable Replacement Vespa PX 150 USA Time TIME 127 ...

Page 128: ... Replacement 2 002063 Throttle cable assy Replacement 3 002053 Rear brake transmission complete replacement 4 003060 Rear brake cable Adjustment 5 003061 Accelerator transmission Adjust ment 6 002045 Clutch cable Replacement Time Vespa PX 150 USA TIME 128 ...

Page 129: ...ipers BRAKE CALLIPERS Code Action Duration 1 003070 Front brake pads Wear check 2 002007 Front brake pads Removal and re fitting 3 002039 Front brake calliper Removal and refitting Vespa PX 150 USA Time TIME 129 ...

Page 130: ...Steering column STEERING COLUMN Code Action Duration 1 003010 Front suspension Service Time Vespa PX 150 USA TIME 130 ...

Page 131: ...Front suspension FRONT SHOCK ABSORBER Code Action Duration 1 003011 Front shock absorber Removal and Refitting Vespa PX 150 USA Time TIME 131 ...

Page 132: ...REAR BRAKE PEDAL Code Action Duration 1 002014 Brake pedal Removal and refitting FRONT WHEEL HUB Code Action Duration 1 003033 Front wheel hub Replacement 2 002041 Brake disc Replacement Time Vespa PX 150 USA TIME 132 ...

Page 133: ...e Action Duration 3 003040 Front wheel bearings Replacement REAR BRAKE SHOES Code Action Duration 1 002002 Rear brake shoe s Replacement 2 003071 Rear brake shoe s Wear check Vespa PX 150 USA Time TIME 133 ...

Page 134: ...SHOE PLATE Code Action Duration 1 002016 Rear brake shoe plate Replace ment 2 003012 Brake shoe plate Removal and Re fitting Time Vespa PX 150 USA TIME 134 ...

Page 135: ...rum Replacement 2 001016 Rear wheel Replacement 3 004026 Handlebar cover Replacement 4 001071 Rear wheel rim Removal and refit ting Clutch cover CLUTCH COVER Code Action Duration 1 001073 Clutch cover Removal and refitting Clutch Vespa PX 150 USA Time TIME 135 ...

Page 136: ...CLUTCH Code Action Duration 1 001022 Clutch Removal Gear box GEAR BOX Code Action Duration 1 001119 Gearbox components Replacement 2 001025 Gearbox Overhaul Time Vespa PX 150 USA TIME 136 ...

Page 137: ...r shifter GEAR SHIFTER Code Action Duration 1 001029 Gear shifter Overhaul GEAR SHIFTER FASTENERS Code Action Duration 1 001077 Gear shifter components Removal and refitting Vespa PX 150 USA Time TIME 137 ...

Page 138: ...Brake 81 82 84 85 129 Brake fluid C Carburettor 10 28 61 62 64 104 F Fuel 62 90 113 Fuses 45 H Headlight 30 87 Horn I Instrument panel 119 M Maintenance 7 24 S Shock absorbers 79 Spark plug 29 T Tank 90 113 114 Transmission 9 Tyres 10 ...

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VESPA PX 150 USA, Workshop Manual

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